HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

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HARLEY DAVIDSON DETACHABLE TOUR-PAK LIGHT HARNESS KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. 2. ALL models: Install the Detachable Tour-Pak Rack Kit per the instructions in that kit, up to the point where the saddlebags are to be re-installed. NOTE Make note of the cable strap locations before releasing the harness from the upper frame tube. New straps will be fastened in the same location. 3. Cut the larger cable strap fastening Tour-Pak circuit [12] (see the Service Manual Wiring Diagram) of the vehicle main harness to the left-side upper frame tube, rearward of the shock absorber. Cut the small cable strap at the end of the circuit [12] conduit. 4. Slit the conduit open along its length to expose the final ten inches (0.25 M) of main harness circuit [12] wiring. Cut the three wires (Black, Blue, and Red with Yellow tracer) nine inches (0.23 M) from the three-way Multilock socket housing [12B]. The socket housing and cut wires can be discarded. 5. Obtain the socket housing, secondary lock (locking wedge), and three socket terminals from the kit. See the illustration at DEUTSCH ELECTRICAL CONNECTORS: REMOVING/INSTALLING SOCKETS in the Service Manual. Refer to CRIMPING INSTRUCTIONS in the Service Manual, and follow the instructions to install the terminals to the three wire leads of main harness circuit [12]. 6. Per the instructions under DEUTSCH ELECTRICAL CONNECTORS, insert the Blue lead and terminal into Cavity 1 of the new socket housing. Insert the Red/Yellow lead and terminal into Cavity 2. Insert the Black lead and terminal into Cavity 3. 7. Cut the excess conduit from main harness circuit [12]. 8. Obtain the two cable straps from the kit. As noted in Step 3, use one strap to bind the end of the main harness circuit [12] conduit. Use the second strap

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